Paint - Inspections Work and Equiptment ### PDF

Frosio course hand-out: Section 17A Inspection work & equipment
Use of instruments
Frosio 17A Inspection work & equipment slide # 1
Inspection Equipment
Utstyr utlagt
1
Inspection after application

After application
the following must be checked
x Climatic conditions (Ventilation,
Temperature and humidity)
x Curing / drying of the film
x Dry film thickness (DFT)
x Adhesion
x Holiday detection (if required)
ISO 2808 - 97 Method No.1

Wet film measuring comb
Microns Wet paint

250 225 200 175 150 125 100 75 50 25
Steel
2
ISO 2808
Wet film thickness gauge
Measure wet paint film
Here: 25 microns between the teeth
0459-21
4932-81
Using PIG Universal on a

ships hull
PIG = Paint
Inspection Gauge
Destructive test
method
Possible to verify
the number of coats
applied Cd-4932-100
Possible to measure
the thickness of
each individual coat
3
PIG Paint Inspection Gauge

Mainly for laboratory use
4932-100
ISO 2808 - 97
Determination of film thickness
Method No. 6: Magnetic method

Magnetic induction principle (Method 6 A)
Permanent magnetic principle (Method 6 B)
Instruments for magnetic, metallic substrates
Calibration must be done in accordance
with instructions from the manufacturer
Before testing the paint system
must be properly cured.
4
ISO 2808 - 97
Method No. 7 - Eddy current method
High frequency electromagnetic

instrument
For non-magnetic substrates
Calibration in accordance with the

manufacturers instruction
ISO 2808 - 97
Method No. 10 - On blast cleaned steel substrates
Electromagnetic instruments
Calibration on a smooth steel surface min. 1,2 mm
thick
For DFT measurement, not less than 25 and
preferably above 50 microns
Number of readings, as a guide:
1 reference area: At least 3 readings evenly
2 reference areas for every square meter for flat plates
4 reference areas for every length for a web
2 reference areas every metre length for a flange
2 reference areas every metre length for a pipe
5
ISO 2808 - Magnetic and electromagnetic

Dry film thickness gauges
Dry film thickness gauge
Calibrate on smooth
surface to zero and to
thickness similar to be
measured
Check with your
calibration foil frequently
Plastic material foils wear
easily. Replace
Cd-4932-82
frequently.
No internal memory in
gauge
ISO 2808 - Magnetic and electromagnetic

Dry film thickness gauges

Calibrate on smooth
measured
Check with your calibration
foil frequently
Plastic material foils wear
easily. Replace frequently.
No internal memory in
gauge
Inspection \ Dryfilmthickness1
6
Magnetic and Electromagnetic

Dry Film Thickness Gauges
ISO 2808
Calibrate on smooth
measured
Check with your
calibration foil frequently
Plastic material foils Trrfilm mlere Elektr.
wear easily. Replace Magn.
frequently.
Some models have
internal memory.
SSPC - PA 2
Measuring DFT on small areas
Procedure
1. Area of 10 m2: 5 spot measurements
2. Each spot measurement: The average of 3 individual

readings made on one small area
3. The average of 5 spot measurements must be

within specified range of film thickness
4. Single spot measurements may be as low as 80% of

specified minimum film thickness
5. Individual readings included in the spot

measurements may be less than 80% of minimum
thickness
7
SSPC - PA 2
Number of film thickness measurements
Case Area Selection of Measurements

1. 10 m2 5 spots (on each spot: 3 measurements)
2. 30 m2 As for case 1 for each 10 m2
3. Up to100 m2 Select 3 areas, each of 10 m2
4. Above 100 m2 The first 100 m2 as for case 3

For each following 100 m2 select
randomly one area of 10 m2
Note: If measurements outside the specification for any 10 m2 in case

3 or 4 above are found, then each 10 m2 shall be measured
Instruments for measuring

surface roughness
Stylus instruments
Elcometer Mod. 123
Testex Press-O-film
Microscope
Comparator
Rugotest No. 3
ISO 8503 etc.
8
Surface Roughness acc. to

ISO 8503
Example of a reference
comparator: Clemco
Surface profile comparator
comprising four segments.
Clemco - grit
Clemco shot also available
Clemco
Check if the profile is
according to specification Compartor
and the paint manufacturers
recommendation
Using Inspection Tools: Mirror and

Flash light
Visual inspection
Important tools to
be able to inspect
areas difficult to
access
Jan, speil, lykt
9
ISO 8502 4 Humidity
Guidance on the estimation of the probability

of condensation prior to paint application
1. Air temperature
2. % Relative humidity
3. Steel temperature
4. Dew point
Steel temperature min. 3 oC above the dew point
Contact Thermometer
Electronic instrument
for measuring the steel
temperature
Steel temperature
must be min. 3oC
above the dew point
Other types of
thermometers are also
available. E.g.
magnetic Steel temperature
thermometers
10
Measuring the Relative Humidity
ISO 8502 - 4
Photo: Sling hygrometer
for measuring:
- Dry temperature
- Wet temperature
Measure the temperature
in the vicinity of the work
Calculate the relative
humidity
Use together with dew
point calculator
Dew Point Calculator

ISO 8502 - 4
For calculation of dew
point
To be used together with
surface temperature
thermometer and sling
hygrometer.
Use this frequently during
pre-treatment, application
and drying of the paint.
Recommendation: Every 6
hours and when weather
conditions are changing
11
Salt Test Equipment - Bresle Test
ISO 8502 - 6
(Sampling)
ISO 8502 - 9
(Conductivity)
Equipment for
sampling and
measuring content of
water soluble salt on
substrate
Bresle method Bresle sett
How to measure the salt level on

a surface
Water soluble salts will be
removed by water jetting
Here: The substrate is
cleaned at a pressure of
2000 bar
Salt level is measured by
the Bresle method
Dissolve the salt inside
the frame of the patch For 15 ml sample size, multiply
Measure the conductivity conductivity measured in S by a
of the water sample factor of 6 to get mg salt per m2
Pre-treatment: Wj_saltlevel1
12
Calculating salt level on the

substrate
Formula: (L2 L1) x 6 = mg salt per m2

L2 = S after cleaning
L1 = S before cleaning
Water sample, ml: 10 15 20 50

Constant in formula: 4 6 8 20
Assessment of Dust on Steel Surfaces

Prepared for Painting. ISO 8502-3
Tape Blast cleaned steel
Approved
Not approved
13
ASTM D 4752-87
Curing test of Zinc - ethylsilicate with MEK.
Glove MEK Rag
Rubbing 50 x
No Zinc on the Rag: A lot of Zinc on Rag:

Cured Not cured
Approved Further curing / Reblasting
14
ASTM D 4752-87
MEK curing test of zinc ethyl silicate
Left: One cured and uncured test plate
Right: Uncured zinc over coated. Result: Delamination
0807-2
A-4
ASTM D 4752-87
Curing test of Zinc ethyl silicate with MEK.
Glove
MEK
Inspection / Zincsilicate_curing1
Rag
15
ASTM D 3359-87
Adhesion testing by knife and adhesive tape
There are two test methods

The method to select depends on the DFT
Method A: DFT above 125 microns

Method B: DFT below 125 microns
(Above 125 if wider cuts are used)
Method A: X - cut. Tape test

Method B: Cross - cut. Tape test
ASTM 3359-87. Method B

Adhesion testing
< 50 microns = 1 mm apart (11 cuts)
50 - 125 microns = 2 mm apart (6 cuts)
> 125 microns = Method A
1. Cuts: 20 mm long
2. Brush with a soft brush
3. Examine
4. Cuts: 20 mm long at 90o on the original cuts
5. Brush with...
6. Tape 75 mm
7. Within 90 + 30 sec. remove tape
16
Classification of adhesion test results.

Method B. (Example for six parallel cuts).
5B None 5B The edges of the cuts are completely
smooth; none of the lattice is detached
4B 4B Small flakes of the coating is detached at
intersections: 5% of the area is affected
3B Small flakes of the coating are detached
along edges and at intersections of cuts.
3B The area affected is 5 to 15% of the
lattice.
2B The coating has flaked along the edges
2B and on parts of the squares. The area
affected is 15 to 35% of the lattice.
1B The coating has flaked along the edges of
1B cuts in large ribbons and whole squares
have detached. The area affected is 35 to
65 % of the lattice.
0B Flaking and detachment worse than Grade
0B Greater than 65% 1B.
ISO 2409
Cross-cut test
Cutting tool
Single bladed knife
or
Multi-blade cutting tool with 6 cutting
edges spaced 1 mm or 2 mm apart
Spacing of cuts
0 - 60 microns: 1 mm spacing, hard substrates
0 - 60 microns: 2 mm spacing, soft substrates
60 - 120 microns: 3 mm spacing, hard/soft substrates
121 - 250 microns: 3 mm spacing, hard/soft substrates
17
ISO 2409
Cross-cut test
Procedure:
Make 6 parallel cuts with defined space in the
coating.
Repeat operation, crossing original cuts at 90o
so that a grid pattern is formed.
Brush with soft brush.
Apply adhesive tape and pull off.
Classify results in accordance with table 1.
ISO 2409
Cross cut adhesion test
Cross cut adhesion

test
Cut vertical and
horizontal lines to
form a grid
Apply a strong tape
Pull off the tape Cd-4932-91
Evaluate according to
the standard
18
ISO 2409
Cross-cut adhesion test
Left: A good type of cross-cut tool

Right: Evaluation of performed test
0002-002
0002-001
Classification of Adhesion Test Results.

(Example for six parallel cuts).
5B None 5B The edges of the cuts are completely

smooth; none of the lattice is detached
4B 4B Small flakes of the coating is detached at
intersections: 5% of the area is affected
3B Small flakes of the coating are detached
along edges and at intersections of cuts.
3B The area affected is 5 to 15% of the
lattice.
2B The coating has flaked along the edges
2B and on parts of the squares. The area
affected is 15 to 35% of the lattice.
1B The coating has flaked along the edges of
1B cuts in large ribbons and whole squares
have detached. The area affected is 35 to
65 % of the lattice.
0B Flaking and detachment worse than Grade
0B Greater than 65% 1B.
19
ISO 2409
Classification of Cross-cut test
Classi- Appearance of surface
Description
fication Six parallel cuts
0 Completely smooth: none of the squares detached
1 Small flakes at the Intersections. Area affected 5 %
Flaked along the edges and/or at the

2 Intersections. Area affected: 5-15%
Flaked along the edges, wholly in large ribbons,

3 and/or partly or wholly on different parts of
the squares. Area affected: 15-35%
Flaked along the edges in large ribbons and/or
4 some squares have detached partly or wholly.
Area affected: 35-65%
5 Any degree of flaking that cannot even be classified by 4.
ISO 2409
Cut vertical and
horizontal lines to form
a grid
Apply a strong tape
Pull off the tape
Evaluate according to
the standard
Inspection / Adhesion_crosscut1
20
ISO 4624
Pull-off test for adhesion
Instruments:
Elcometer Adhesion Tester
Saeberg Adhesion Tester (pneumatic)
Hate Adhesion Tester (hydraulic)
PAT
Other
Failure:
Adhesion failure: Between coats or between or substrate and 1st coat
Cohesion failure: Inside a coat
ISO 4624
Pull-off test for adhesion
Procedure:
Test dollies glued onto the coating
Adhesive: Cyano-acrylate or solvent free epoxy
Remove adhesive and coating around the dollies
Pull off test-dollies vertical to the surface
Read adhesion value and report the type of fracture
Fractures:
Adhesion failure - fracture between coats or substrate and 1.
coat
Cohesion failure - fracture within a coat
21
ISO 4624
Pull-off dollies glued to the structure
Pull off adhesion
test
Dollies are glued to
the structure with a
strong glue
Prior to pull-off:
Cut around the Cd-4932-102
dolly, through the
paint film and down
to the substrate
material
ISO 4624
Pull-off testing of paint on a structure
Pull off adhesion test.
Destructive test method
Here, connecting of the
device for pulling off the
dollies
Read and note the value
Several types of Cd-4932-101
instruments are
available
22
ISO 4624
Area after pull-off testing
Pull off adhesion test
The adhesive failure -
fracture between coats -
or between coating and
substrate must be
evaluated Cd-4932-103
Note adhesion failure, %
The cohesive failure -
fracture within the
coating- must be
evaluated.
Note cohesion failure, %
Also: Note glue failure, %
ISO 4624
Pull-off dollies glued to the
structure
Pull off adhesion test
Dollies are glued to the
structure with a strong
glue
Prior to pull-off:
Cut around the dolly,
through the paint film
and down to the
substrate material
Record the pull-off
value Inspection / Adhesion_pulloff1
Evaluate the failure
23
ASTM G 62 - 85 Method A
Pinhole detection. Low voltage.
Low voltage: < 75 V DC

To detect pinholes, voids or metal particles to
be in the range of 25-250 microns.
Effective for paint films up to a DFT of 500
microns if a wetting agent is used in the
water.
This is a non-destructive test.
ASTM G-62-85, method A

Low voltage holiday detector
Photo: Low voltage
pinhole detector
Detecting pinholes, voids
or metal particles in paint
film up to 250 microns
Non destructive test
method
Will only detect defects Cd-4932-92
down to bare metal
The sponge must be
wetted
Do not use excessive
water
24

Low voltage pinhole detector
Photo: Low voltage pinhole
detector
Detecting pinholes, voids
or metal particles in paint
film up to 250 microns
method
Will only detect defects
down to bare metal 0002-004
The sponge must be
wetted
Do not use excessive water

Low voltage pinhole detector
Detecting pinholes,
voids or metal
particles in paint film
up to 250 microns
method
Will only detect defects
down to bare metal
The sponge must be
wetted
Do not use excessive Inspection / Pore_detection1
water
25
ASTM G 62 Method B
Holiday detection. High voltage.
High voltage: 900 - 20.000 V
Used to detect pinholes, voids and

areas with thin paint films
This is a destructive test.
ASTM G-62-85, method B

High voltage holiday detector
for detecting pinholes,
voids and thin spots in
paint film
Adjust voltage according to
the film thickness or the
paint manufacturers Cd-4932-93
recommendation
Gives a light or signal when
pinhole or weak point is
detected
26
ASTM G-62-85, method B

High voltage holiday detector

for detecting pinholes,
voids and thin spots in
paint film
Adjust voltage according to
the film thickness or the
0002-005
paint manufacturers
recommendation
Gives a light or signal when
pinhole or weak point is
detected
ASTM G 62 Method B
Holiday detection. High voltage.
High voltage: 900 - 20.000
V
Used to detect pinholes,

voids and
areas with thin paint films
This is a destructive test.
Inspection / Holiday_detection1
27
ISO 12944
General standard for corrosion protection:
Paints and varnishes - Corrosion protection
of steel structures by protective paints systems.
Part 1 General introduction.
Part 2 Classification of environments.
Part 3 Design considerations.
Part 4 Types of surface and surface preparation.
Part 5 Protective paint systems.
Part 6 Laboratory performance test methods.
Part 7 Execution and supervision of paint work.
Part 8 Development of specifications for new work
and maintenance.
ISO 8504 - 1
General principles
Selection of methods
28
ISO 8504
Surface preparation methods:
Part 1: General principles.

Part 2: Abrasive blast-cleaning.
Part 3: Hand- and power-tool
cleaning.
ISO 8504 - 2
Abrasive blast-cleaning
Methods
Effectiveness
Fields of
application
29
ISO 8504 - 3
Hand and Power-tool Cleaning
Methods
Equipment to be used
Procedure to be followed
Using solvents to determine

generic type of paint
Paint dissolves:
Rag soaked Physically drying
with solvent
No reaction:
Chemically curing
Steel
Lifting/Wrinkling:
2 coat paint Oxidatively curing
30
Using solvents to determine

generic type of paint
Use a rag soaked
with solvent
No reaction:
Chemically curing
Paint dissolves:
Physically drying
Lifting/Wrinkling: Inspection / Determine_generic1

Oxidatively curing
Standards relating to mechanical properties

Property Standard / Test method
Adhesion (Cross cut) ISO 2409, DIN 53251, BS 3900-E6, ASTM 3359
Adhesion (Pull-off) ISO 4624, ASTM 4541, BS 3900 - E10
Adhesion ASTM D 1002 (Specified for Chartek)
(Shear strength)
Hardness ISO 2815 (Buchholz - methode)
Hardness ISO 1522 (Knig - pendel)
Hardness Barchol
Elasticiy ISO 1520 (Cupping test)
Flexibility ISO 6860 ASTM D 522
BS 3900 - E11 (Conical mandrel)
Impact resistance ISO/TR 6272 - 79E ASTM D 2794 - 84
DIN 55669 BS 3900 - E3
31
Testing and evaluation.

marine atmosphere (1 of 2)
Test method Standards Comments
Physical testing
Adhesion ISO 2409 Before and after exposure
Adhesion ISO 4624 Before and after exposure
Flexibility ISO 1510 Before and after exposure
Elasticity ISO 1520 Before and after exposure
Hardness ISO 2815
Impact resistance ISO 6272
Gloss ISO 2813
Abrasion resistance ASTM D 4060
Exposure conditions:
Saltspray ISO 7253 or ASTM B 117
Prohesion test
UV-cabinet ASTM G 53
Condensation chamber ISO 6270
Humidity chamber BS 3900
Weathering ISO 2810
Resistance to liquids ISO 2812 Oil, petroleum , etc.
Testing and evaluation.

marine atmosphere (2 of 2)
Test method Standards Comments
Evaluation of paint films

Blistering ISO 4628/2
Rust ISO 4628/3
Cracking ISO 4628/4
Flaking ISO 4628/5
Chalking ISO 4628/6
Scribe ASTM D 1654
Evaluation of the liquid paint

Appearance in tin ISO 2431 Flow time
Viscosity ISO 2884
Application properties
32
Abrasion resistance
Weigh the painted
sample
Install it in the apparatus
and run 1000 cycles
Measure the weight loss
Testing paints \ Abrasion resistance1
Flexibility test
Use a thin test panel
Measure the paint film
thickness
Carry out the impact test
on the rear side of the
test panel
Determine the highest
level of impact load
before any crack or
defect in the paint film
occurs
Testing paints \ Flexibility_test1
33
Impact test
Use a thick test panel
Measure the paint film
thickness
Carry out the impact test
on the painted side of the
test panel
Determine the highest
level of impact load
before any crack or
defect in the paint film
occurs
Testing paints \ Impact_test1
Reference area should:
be representative to the remaining

area coated with the same system.
be available for inspection at any time.
be marked thoroughly to indicate
"ref.area"
not be overcoated
34
Controlled application
Inspection of:
steelwork
cleaning
surface preparation (blastcleaning)
painting
curing
completed system
Number of reference areas

Size of structure Recommended maximum Recommended maximum Recommended maximum
(painted area) Number of reference percentage of reference total area of reference
m2 areas area relative to total area areas
of structure m2
< 2000 3 0,6 12
2000 to 5000 5 0,5 25
5000 to 10000 7 0,5 50
10000 to 25000 7 0,3 75
25000 to 50000 9 0,2 100
>50000 9 0,2 200
35

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Frosio course hand-out: Section 17A Inspection work & equipment

Frosio 17A Inspection work & equipment slide # 1

Frosio 17A Inspection work & equipment slide # 2

Inspection after application

Frosio 17A Inspection work & equipment slide # 3

ISO 2808 - 97 Method No.1

Microns Wet paint

Frosio 17A Inspection work & equipment slide # 4

Frosio 17A Inspection work & equipment slide # 5

Using PIG Universal on a

Frosio 17A Inspection work & equipment slide # 6

PIG Paint Inspection Gauge

Frosio 17A Inspection work & equipment slide # 7

Method No. 6: Magnetic method

High frequency electromagnetic

For non-magnetic substrates

Calibration in accordance with the

Frosio 17A Inspection work & equipment slide # 9

Frosio 17A Inspection work & equipment slide # 10

ISO 2808 - Magnetic and electromagnetic

Frosio 17A Inspection work & equipment slide # 11

ISO 2808 - Magnetic and electromagnetic

Dry film thickness gauge

Frosio 17A Inspection work & equipment slide # 12

Magnetic and Electromagnetic

Frosio 17A Inspection work & equipment slide # 13

2. Each spot measurement: The average of 3 individual

3. The average of 5 spot measurements must be

4. Single spot measurements may be as low as 80% of

5. Individual readings included in the spot

Frosio 17A Inspection work & equipment slide # 14

Case Area Selection of Measurements

2. 30 m2 As for case 1 for each 10 m2

3. Up to100 m2 Select 3 areas, each of 10 m2

4. Above 100 m2 The first 100 m2 as for case 3

Note: If measurements outside the specification for any 10 m2 in case

Frosio 17A Inspection work & equipment slide # 15

Instruments for measuring

Frosio 17A Inspection work & equipment slide # 16

Surface Roughness acc. to

Frosio 17A Inspection work & equipment slide # 17

Using Inspection Tools: Mirror and

Frosio 17A Inspection work & equipment slide # 18

ISO 8502 4 Humidity

Guidance on the estimation of the probability

Steel temperature min. 3 oC above the dew point

Frosio 17A Inspection work & equipment slide # 19

Frosio 17A Inspection work & equipment slide # 20

Measuring the Relative Humidity

Frosio 17A Inspection work & equipment slide # 21

Dew Point Calculator

Frosio 17A Inspection work & equipment slide # 22

Salt Test Equipment - Bresle Test

Frosio 17A Inspection work & equipment slide # 23

How to measure the salt level on

Frosio 17A Inspection work & equipment slide # 24

Calculating salt level on the

Formula: (L2 L1) x 6 = mg salt per m2

Water sample, ml: 10 15 20 50

Frosio 17A Inspection work & equipment slide # 25

Assessment of Dust on Steel Surfaces

Tape Blast cleaned steel